A Quick Guide to API 510 Certied Pressure Vessel Inspector Syllabus

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QG Publishing is a Matthews Engineering Training Ltd company

MATTHEWS
ENGINEERING TRAINING LTD
www.matthews-training.co.uk

Training courses for industry

. . . . . . Plant in-service inspection training Pressure systems/PSSR/PED/PRVs Notied Body training Pressure equipment code design ASME/BS/EN API inspector training (UK) : API 510/570/653 On-line training courses available

Matthews Engineering Training Ltd provides training in pressure equipment and inspection-related subjects, and the implementation of published codes and standards. More than 500 classroom and hands-on courses have been presented to major clients from the power, process, petrochemical and oil/gas industries. We specialize in in-company courses, tailored to the needs of individual clients. Contact us at [email protected] Tel: +44(0) 7732 799351
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A Quick Guide to

API 510 Certied Pressure Vessel Inspector Syllabus

Example Questions and Worked Answers

Clifford Matthews

Series editor: Clifford Matthews

Matthews Engineering Training Limited www.matthews-training.co.uk

Oxford

Cambridge

New Delhi

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Published by Woodhead Publishing Limited, Abington Hall, Granta Park, Great Abington, Cambridge CB21 6AH, UK www.woodheadpublishing.com and Matthews Engineering Training Limited www.matthews-training.co.uk Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj, New Delhi 110002, India Published in North America by the American Society of Mechanical Engineers (ASME), Three Park Avenue, New York, NY 10016-5990, USA www.asme.org First published 2010, Woodhead Publishing Limited and Matthews Engineering Training Limited # 2010, C. Matthews The author has asserted his moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the author and the publishers cannot assume responsibility for the validity of all materials. Neither the author nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microlming and recording, or by any information storage or retrieval system, without permission in writing from Woodhead Publishing Limited. The consent of Woodhead Publishing Limited does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specic permission must be obtained in writing from Woodhead Publishing Limited for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identication and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress. Woodhead Publishing ISBN 978-1-84569-755-6 Woodhead Publishing ISBN 978-0-85709-102-4 ASME ISBN 978-0-7918-5962-9 ASME Order No. 859629 ASME Order No. 85962Q (e-book) (print) (online)

Typeset by Data Standards Ltd, Frome, Somerset, UK Printed in the United Kingdom by Henry Ling Limited

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Contents

The Quick Guide Series How to Use This Book Chapter 1: Interpreting ASME and API Codes 1.1 Codes and the real world 1.2 ASME construction codes 1.3 API inspection codes 1.4 Code revisions 1.5 Code illustrations 1.6 New construction versus repair activity 1.7 Conclusion: interpreting API and ASME codes Chapter 2: An Introduction to API 510 (Sections 14) 2.1 Introduction 2.2 Section 1: scope 2.3 Section 3: denitions 2.4 Section 4: owner/user/inspector organization 2.5 API 510 sections 14 familiarization questions Chapter 3: API 510 Inspection Practices (Section 5) 3.1 Introduction to API 510 section 5: inspection practices 3.2 Inspection types and planning 3.3 Condition monitoring locations (CMLs) 3.4 Section 5.8: pressure testing 3.5 API 510 section 5 familiarization questions Chapter 4: API 510 Frequency and Data Evaluation (Sections 6 and 7) 4.1 Introduction 4.2 The contents of section 6 4.3 API 510 section 6 familiarization questions 4.4 Section 7: inspection data evaluation, analysis and recording 4.5 API 510 section 7 familiarization questions

x xii 1 1 2 5 5 6 7 10 10 13 16 20

23 23 27 27 30

33 34 40 42 56

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Quick Guide to API 510

Chapter 5: API 510 Repair, Alteration, Re-rating (Section 8) 5.1 Denitions 5.2 Re-rating 5.3 Repairs 5.4 API 510 section 8 familiarization questions Chapter 6: API 572 Inspection of Pressure Vessels 6.1 API 572 introduction 6.2 API 572 section 4: types of pressure vessels 6.3 API 572 section 4.3: materials of construction 6.4 API 572 sections 5, 6 and 7 6.5 API 572 section 8: corrosion mechanisms 6.6 API 572 section 9: frequency and time of inspection 6.7 API 572 section 10: inspection methods and limitations 6.8 API 572 section 10 familiarization questions Chapter 7: API 571 Damage Mechanisms 7.1 API 571 introduction 7.2 The rst group of DMs 7.3 API 571 familiarization questions (set 1) 7.4 The second group of DMs 7.5 API 571 familiarization questions (set 2) 7.6 The third group of DMs Chapter 8: API 576 Inspection of Pressure-Relieving Devices 8.1 Introduction to API 576 8.2 API 576 sections 3 and 4: types (denitions) of pressure-relieving devices 8.3 Types of pressure-relieving device 8.4 API 576 section 5: causes of improper performance 8.5 API 576 section 6: inspection and testing 8.6 API 576 familiarization questions Chapter 9: ASME VIII Pressure Design 9.1 The role of ASME VIII in the API 510 syllabus 9.2 How much of ASME VIII is in the API 510 syllabus?

61 62 68 72 75 77 78 80 80 82 82 84 89 93 94 97 98 99

105 106 108 115 119 120 124 125

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Contents

ASME VIII clause numbering 128 Shell calculations: internal pressure 130 Head calculations: internal pressure 134 Set 1: shells/heads under internal pressure familiarization questions 141 9.7 ASME VIII: MAWP and pressure testing 143 9.8 Set 2: MAWP and pressure testing familiarization questions 152 9.9 External pressure shell calculations 155 9.10 Set 3: vessels under external pressure familiarization questions 160 9.11 Nozzle design 161 Chapter 10: ASME VIII Welding and NDE 10.1 Introduction 171 10.2 Sections UW-1 to UW-5: about joint design 171 10.3 UW-12: joint efciencies 175 10.4 UW-11: RT and UT examinations 177 10.5 UW-9: design of welded joints 179 10.6 ASME VIII section UW-11 familiarization questions (set 1) 180 10.7 Welding requirements of ASME VIII section UW-16 181 10.8 ASME VIII section UW-16 familiarization questions (set 2) 183 10.9 RT requirements of ASME VIII sections UW-51 and UW-52 185 10.10 ASME VIII section UW-51/52 familiarization questions (set 3) 192 Chapter 11: ASME VIII and API 510 Heat Treatment 11.1 ASME requirements for PWHT 195 11.2 What is in UCS-56? 195 11.3 API 510 PWHT overrides 197 11.4 ASME VIII sections UCS-56 and UW-40: PWHT familiarization questions 201 Chapter 12: Impact Testing 12.1 Avoiding brittle fracture 203 12.2 Impact exemption UCS-66 204

9.3 9.4 9.5 9.6

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Quick Guide to API 510

12.3 ASME VIII section UCS-66: impact test exemption familiarization questions Chapter 13: Introduction to Welding/API 577 13.1 Module introduction 13.2 Welding processes 13.3 Welding consumables 13.4 Welding process familiarization questions 13.5 Welding consumables familiarization questions Chapter 14: Welding Qualications and ASME IX 14.1 Module introduction 14.2 Formulating the qualication requirements 14.3 Welding documentation reviews: the exam questions 14.4 ASME IX article I 14.5 Section QW-140 types and purposes of tests and examinations 14.6 ASME IX article II 14.7 ASME IX articles I and II familiarization questions 14.8 ASME IX article III 14.9 ASME IX article IV 14.10 ASME IX articles III and IV familiarization questions 14.11 The ASME IX review methodology 14.12 ASME IX WPS/PQR review: worked example Chapter 15: The NDE Requirements of API 510 and API 577 15.1 NDE requirements of API 510 and API 577 15.2 API 510 NDE requirements Chapter 16: NDE Requirements of ASME V 16.1 Introduction 16.2 ASME V article 1: general requirements 16.3 ASME V article 2: radiographic examination 16.4 ASME V article 6: penetrant testing (PT) 16.5 ASME V articles 1, 2 and 6: familiarization questions 16.6 ASME V article 7: magnetic testing (MT)

211 212 212 215 220 222 225 225 231 233 235 236 237 239 240 243 245 247

257 257 262 262 263 269 273 274

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Contents

16.7 ASME V article 23: ultrasonic thickness checking 16.8 ASME V articles 7 and 23 familiarization questions Chapter 17: Thirty Open-Book Sample Questions Chapter 18: Answers 18.1 Familiarization answers 18.2 Open-book sample questions answers Chapter 19: The Final Word on Exam Questions 19.1 All exams anywhere: some statistical nuts and bolts for non-mathematicians 19.2 Exam questions and the three principles of whatever (the universal conundrum of randomness versus balance) 19.3 Exam selectivity Appendix Publications effectivity sheet for API 510 Exam Administration: 2 June 2010 Index

277 280

292 297

301

303 305

309 312

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The Quick Guide Series

The Quick Guide data books are intended as simplied, easily accessed references to a range of technical subjects. The initial books in the series were published by The Institution of Mechanical Engineers (Professional Engineering Publishing Ltd), written by the series editor Cliff Matthews. The series is now being extended to cover an increasing range of technical subjects by Matthews Engineering Training Ltd. The concept of the Matthews Quick Guides is to provide condensed technical information on complex technical subjects in a pocket book format. Coverage includes the various regulations, codes and standards relevant to the subject. These can be difcult to understand in their full form, so the Quick Guides try to pick out the key points and explain them in straightforward terms. This of course means that each guide can only cover the main points of its subject it is not always possible to explain everything in great depth. For this reason, the Quick Guides should only be taken as that a quick guide rather than a detailed treatise on the subject. Where subject matter has statutory signicance, e.g. statutory regulation and reference technical codes and standards, then these guides do not claim to be a full interpretation of the statutory requirements. In reality, even regulations themselves do not really have this full status many points can only be interpreted in a court of law. The objective of the Quick Guides is therefore to provide information that will add to the clarity of the picture rather than produce new subject matter or interpretations that will confuse you even further. If you have any comments on this book, or you have any suggestions for other books you would like to see in the

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The Quick Guide Series

Quick Guides series, contact us through our website: www. matthews-training.co.uk Special thanks are due to Helen Hughes for her diligent work in typing the manuscript for this book.

Cliff Matthews Series Editor

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How to Use This Book

This book is a Quick Guide to the API 510 Certied Pressure Vessel Inspector examination syllabus (formally called the body of knowledge by API). It is intended to be of use to readers who: . intend to study and sit for the formal API 510 Individual Certication Program (ICP) examination or . have a general interest in the content of API 510 and its associated API/ASME codes, as they are applied to the inservice inspection of pressure vessels. The book covers all the codes listed in the API 510 syllabus (the so-called effectivity list) but only the content that is covered in the body of knowledge. Note that in some cases (e.g. ASME VIII) this represents only a small percentage of the full code content. In addition, the content of individual chapters of this book is chosen to reect those topics that crop up frequently in the API 510 ICP examination. Surprisingly, some long-standing parts of the API 510 body of knowledge have appeared very infrequently, or not at all, in recent examinations. While this book is intended to be useful as a summary, remember that it cannot be a full replacement for a programme of study of the necessary codes. The book does not cover the entire API 510 ICP syllabus, but you should nd it useful as a pre-training course study guide or as preexamination revision following a training course itself. It is very difcult, perhaps almost impossible, to learn enough to pass the exam using only individual reading of this book. This quick guide is structured into chapters each addressing separate parts of the API 510 ICP syllabus. A central idea of the chapters is that they contain self-test questions to help you understand the content of the codes. These are as important as the chapter text itself it is a wellproven fact that you retain more information by actively

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How to Use This Book

searching (either mentally or physically) for an answer to a question than by the more passive activity of simply reading through passages or tables of text. Most of the chapters can stand alone as summaries of individual codes, with the exception of the mock examination questions that contain cumulative content from all of the previous chapters. It therefore makes sense to leave these until last.

Code references dates

The API 510 ICP programme runs several times per year with examinations held in June, September and December. Each examination sitting is considered as a separate event with the examination content being linked to a pre-published code effectivity list and body of knowledge. While the body of knowledge does not change much, the effectivity list is continually updated as new addenda or editions of each code come into play. Note that a code edition normally only enters the API 510 effectivity list twelve months after it has been issued. This allows time for any major errors to be found and corrected. In writing this Quick Guide it has been necessary to set a reference date for the code editions used. We have used the effectivity list for the June 2010 examinations. Hence all the references used to specic code sections and clauses will refer to the code editions/revisions mentioned in that effectivity list. A summary of these is provided in the Appendix. In many cases the numbering of code clauses remains unchanged over many code revisions, so this book should be of some use for several years into the future. There are subtle differences in the way that API and ASME, as separate organizations, change the organization of their clause numbering systems to incorporate technical updates and changes as they occur but they are hardly worth worrying about.

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Quick Guide to API 510

Important note: the role of API

API have not sponsored, participated or been involved in the compilation of this book in any way. API do not issue past ICP examination papers or details of their question banks to any training provider, anywhere. API codes are published documents, which anyone is allowed to interpret in any way they wish. Our interpretations in this book are built up from a record of running successful API 570/510/653 training programmes in which we have achieved a rst-time pass rate of 8590 %+. It is worth noting that most training providers either do not know what their delegates pass rate is or dont publish it if they do. API sometimes publish pass rate statistics check their website www.api.org and see if they do, and what they are.

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